Composite filament and staple yarn



May 15, 1956 BRANT 2,745,240

COMPOSITE FILAMENT AND STAPLE YARN Filed May 18, 1950 TOW OF FILAMENTS OF LOWER EXTENSIBILITY TOW OF HIGHLY EXTENSIBLE FILAMENTS ROLLS COLLECTING DEVICE FOR COMPOSITE YARN ROVING OF STAPLE FIBERS BAC K ROLLS FIG. 2.

MIDDLE ROLLS FRONT ROLLS TOW OF HIGHLY EXTENSIBLE FILAMENTS COLLECTING DEVICE FOR COMPOSITE YARN INVENTOR.

JOSEPH H. BRANT HIS ATTORNEYS United States Patent ice 2,745,240 COMPOSITE FIIJAME NT ANDSTAPLEYARN- Joseph H. Brant, West Auburn; Maine," assignor' tofBates Manufacturing Compauyg-a corporation of Maine Application May 18,1950, Serial No. 162,709

10 Claims. (Cl. 57-140).

The present inventionrelatesto novel'compositeyar'ns and to a method of producing them; Morep'articula'rly, the invention. relates to final yarn" products containing both continuous filaments and staple'fibers'resulting, in a preferred form, ,from "drawing filaments ofidiiferent characteristics whereby some of the filament components are'extended and become highly: oriented and" others become converted to" staples. Filaments and 'rovi-ngs (staples) may also be used; In these'new yarn products the staple fibers become'firmly anchored "to the"fila-= ments', giving a final stabilized yarnprodrictfhfiingthe appearance and feel of a spun "stap'le" yarn but with the superior properties of a filament-yarn;

M any attempts have been "made heretofore-to produce a com' csite'or combination-yarn made up ofeontinuous filaments and staple orspun-'fibers. In' spiteof the advantages that shou'ldre'sult from the: combination-of th'ehigh tensile strength properties ofa y'a'rrn ofcon tinuous filaments and the hand, appearance anddyeirig characteristics of 'a staple or spun' yarn, no such yarns have met withcom'mercial' success: Up=to the present time attempts to produce" a- "st')--'called composite yarn have been unable 'to' eliminate in the yarn the tendehcy ofth'e staple" components to "be-' easily 'peeled otf orbe stripped from the continuous filament componentsi other disadvantage has'rbeen an'uncontrolled elongation with respect to each of the yarn components. ,As a result of an uncontrolled and unbalanced relationshipbetween the yarn components, ayarnhavihg adiif rent" breaking point'foreach of th'e'components results! Sucha condi tion is known as 'a'doublebreak; A'yarn" of' this type isinherently a weak yarn.

It hasnow'been'*found'that'it is possible 'to'produce a new'composite yarn that does not possess these known disadvantages; The new yarn has high tensile "strength; uniform break, high resistance tostrippingjianfgood hand, appearance and dyeing characteristics.

The method of producing the 5 new "yarns consists es sentially of doublinga towfof incompletely;oriented, con tinuous and highly extensible filaments with an'asse'mblage of potential yarn components, which term is intended herein toin'clude a tow or yarn of filaments of substantially 7 lower extensibility and a roving; of 'sta'ple 'fibers. The doubled material is then drafted-toextend"'aiiid'highly orient but not break-the filaments of the previously highly extensible incompletely oriented *tOw; the f drafting, how ever, being .sufiicient to break into staple" form-the lower extensible filament; then twisting these doubled and draft ed filaments andstaples to form a composite yarn which combines and: interlocks the: continuousfilaments and staple-fibers.

Therelatively. unoriented, highly extensible filaments used in practicing the present invention may be any "that have the property of being 'extensible to a high degree, i. e., of the: order of. more than about 100% preferably between 400-800% although the maximum extensibility may be as high as 280095. Fila'ments'which arej suitable for my invention are nylon, a syiith'etic elymeri'e'amide;

2,745,240 Patented May 15, 1956 Vihyo'rf-N", a"'copolymer orvinyl chloride and acryl oiiitrile,polyethylene;.Orlon, a polymer of acrylonitrile; sar'an, availableas Permalon and Velon, polymers and' copolymers of "viiiylidene chloride; and"Dacron, a polyestenofterephthalicacid and ethylene glycol.-

I tfis'knoWn-thafin afilament of this type, long chain molecules are "distributed moreor less at random relative to'theax'is' of 'the'fil amentl When' the'filament'is first spun, the molecules are oriented to a minimum but nevertli'elessperceptible degree. As the filament is stretched, more and'm'ore' of'the long'chain molecules become orientedwith their"axesfparallel to the' axis ofthe filament until a m'aximumdegree oforient'ationis attained. Filamerits in'whichthe molecules "are'hi'ghlybriented, i. e., oriented toa maximum degree, possess high tensile strength; This is'appare'ntlydue to the'parall'el alignment of' themolecules and'the consequently increased intermolecular" friction. Filaments wherein the moleculesare oriented a substantially. less'than -maximum degree, a 'conditi'on referred to herein asrelatively unoriented (st-incompletely oriented, are highly, ex tensible irr'the se'nsein' which this term is used in this description in that they maybe extendedin length at least to 800%"or even'considerably higher without breaking; Unstretched' Vinyori-N filaments, for example, may'bestret'ched asrinuch as 2500%, atelevated temperatures;- without breaking.

In"'accordaneewiththis' invention, the tow of highly extensible "filaments" may be doubled and drafted with a tovv"or yarnof"filamentsof "substantially lower extensihility, i. e.', having. an extensibility'of no more than about 50% the extehs'ibilityofthehighlylextensible filaments'. Thefilanients of high and'low extensibility may be'"oftlie"sattie.or different material, the only requiremnt'being thattliefilamentsoflow extensibility;be no more than about half as extensible asthe highly extensible""filam'e'ntsl" Thefila'm'ents of low extensibilityimay, f0r"exan'1'ple,'be partially orcompletel-y oriented nylon, Vinyon polyethylene, Orlon,saran,' Permalon, Yelb'n, or""D'a'cron," or' of 'viscose,- cellulose acetate, Frtisan: a particular regenerated "cellulose, i. e., highlyorierited"cellulose' acetateco'nverted into cellulose by saponlfication', and the like.- a

The row -of"highly' extensible filaments may also be drafted and doubledwith a roving of staple fibers, such as 'co'tton',"w'ool; and Vicara, a regenerated protein fiber redated from'zeinby the Virginia Carolina Chemical Company,"as'we11 as with a-roving of any of the previouslyfme'ntioned materials in staplized form.

Thedraftingtoperation'is conducted in such a manner as tobrie'nt'mOre-completelythe highly extensible filaments'without breakingthem, while staplizingby drawing and breaking the less extensible continuous filaments or'while'drawing out the roving of staple fibers. The twisting'op'eration may be carried out-before, after or simultaneously'with the drafting, prior or later twisting beingpreferred because it can be carried out more readily on -exi'st'ing'"'textile processing machinery. The drafting can be done to oonstant tension, constant elongation-ora combination of both; Mos'tfextensible filaments are best drawn at a constant rate of elongation and each type has an optimum rate of elongation dependent upon the ambient temperature and humidity -conditionst- Another important feature 'ofthisinvention is therela tionship between the components makingup'the-composite yarn. O bviously, thediiferences-in' extensibility must be such that the-highly exten ible yarn does notbreak before the staplizingof the lowly extensible -yarn.-- Also the difierence in extensibility must be suchthat-the highly extensible yarnbecomes oriented when thedrafting com I pletes" the 'stapliiin g of the tow or yarn of low extensibility.

Iii certain cases it "maybe desirable to extend the highly I extensible filaments in some degree prior to the joint drafting in order to obtain the desired orientation of the highly extensible filaments and to avoid extended distribution of the staples. Another important factor is the component relationship whereby the drafting results not only in the desired orientation and staplizing and interweaving of filaments and staples but gives an end product in which the breaking points of the components are equivalent. This invention results in a composite yarn of great strength, of greater elongation at the break than an equivalent spun yarn, and one of improved stripping characteristics.

The degree of orientation of any given continuous filament at which it possesses its maximum tensile strength is known, or if not known, is readily determinable by those skilled in the art. It is likewise within the skill of the art to determine the breaking points of a yarn of any given continuous, oriented filaments and of a yarn of staple fibers if such breaking points are not already known. For optimum results in accordance with the principles of this invention, a tow of highly extensible filaments and a tow of less extensible filaments or roving of staple fibers are so selected for codrafting and twisting that the breaking point of the oriented filaments in the resulting composite yarn will be substantially equal to or greater than the breaking point of the staplized or staple fiber component and the tensile strength of the oriented filaments will be at a maximum. By proper selection of the codrafted assemblage of highly extensible filaments and lowly extensible filaments or staple fibers, a compo-site yarn having substantially a single break upon tensioning to the breaking point is obtained as a result of the codrafting.

Two typical arrangements for carrying out the method of this invention are illustrated, by way of example only, in the accompanying drawing wherein:

Figure 1 is a diagrammatic view of an arrangement of apparatus for codrawing two tows of continuous filaments, one tow containing filaments of substantially higher extensibility than the other; and

Figure 2 is a similar view of an arrangement of apparatus for codrawing a tow of continuous filaments with a roving of staple fibers.

One of the primary advantages of the product of this invention is that it combines the desirable high strength characteristics of oriented continuous filament yarns with the hand, appearance, dyeing characteristics and weaving properties of staple yarns. The composite yarn of this invention has a construction resisting the peeling back of the staple components from the continuous components.

The primary advantages of the method of the invention reside not only in the simplicity of the operation but also in the ability to use directly unoriented and undrafted filaments of polymeric materials. This is a considerable advantage inasmuch as it permits the textile manufacturer to carry out operations within his field utilizing products of lower cost than predrawn filaments. Also the capacity of the chemical manufacture is limited by the capacity for drafting and orienting the filaments which they produce. This invention therefore acts to increase the available supply of finished textile fibers.

These advantages, as well as the objects and utility of the invention, will become more apparent from the following examples which are intended to illustrate a number of typical embodiments of the invention.

Example 1 An untwisted tow of 34 non-elongated nylon filaments having a total denier of 1065 was supplied to a tow spinning frame and adjacent to it was placed a package Conventional methods of starting the tow doubled filaments to a common spindle. The front rolls were operated at approximately five times the peripheral speed of the back rolls so that the elongation of the tows was in the neighborhood of 400%. After the drawing operation, the yarns were given a twist of approximately 2 /2 turns per inch.

It was found that the nylon filaments were substantially continuous and highly oriented and that the viscose fibers varied in length from a fraction of an inch up to about nine inches, i. e., the distance between the rolls. The viscose fibers were firmly anchored to the nylon filaments and resisted efforts to peel them back.

Example 2 An untwisted tow of 240 non-elongated Vinyon-N (Grade NOHI-125) having a total denier of 650 was supplied to a tow spinning frame and adjacent to it was placed a package of a 2200 denier viscose tow containing approximately 735 filaments. The two tows were directed to a common back roll of the spinning frame, over the apron and through the front rolls which were nine inchesfrom the back rolls. The ambient temperature was maintained at between 70 and F. Conventional methods of starting the tow spinner were followed, which may include taking the doubled filaments to a common spindle. The front rolls were operated at approximately 2.2 times the peripheral speed of the back rolls so that the elongation of the tows was in the neighborhood of After the drawing operation, the yarns were given a twist of approximately 2 /2 turns per inch.

The yarn produced possessed a tensile strength considerably higher than the tensile strength of a similar size yarn prepared from tow spun viscose alone and the properties of the yarn with respect to dyeing, handle, appearance, etc., were found to be substantially those of viscose.

Other types of Vinyon yarns can be drawn and oriented to a high degree at temperatures of about C. However, if such temperatures are not used the yarns may be used as those of low extensibility having a range of 20-30%. Cellulose acetate yarns are of an even lower order of extensibility.

Example 3 An untwisted tow of 34 non-elongated nylon filaments having a total denier of 452 was supplied to a tow spinning frame and adjacent to it was placed an untwisted tow of 34 nylon filaments prestretched 480% and having a total denier of 1065. The two tows were directed to a common back roll of the spinning frame, over the apron and through the front rolls, which were nine inches from the back rolls. Conventional methods of starting the tow spinner were followed, which may include taking the doubled filaments to a common spindle. The front rolls were operated at approximately five times the peripheral speed of the back rolls so that the elongation of the tows was in the neighborhood of 400%.

The prestretched nylon filaments were broken into staples up to about nine inches in length and were uniformly distributed along the length of the yarn produced. The yarn had the general characteristics of tow spun nylon as far as physical appearance, handle, etc., are concerned but possessed a strength higher than the strength exhibited by tow spun nylon yarn of the same denier. Furthermore, the yarn was made with a twist multiplier lower than is possible with spun nylon alone. This is a distinct advantage in that lowered twist contributes to higher loft and consequently better covering power when such yarns are woven into fabrics. It also simplifies the manufacture of napped or brushed fabrics.

Example 4 A 20 filament tow of non-elongated polyethylene having a denier of 700 was supplied to a conventional cotton spinning" frame co-incidentally with a nylon roving ot 1L5 denier, l'.-5' "staple "and ithe two wer'e carried-{res gether' to' the --middle".rolli o f the fr'an're, over tlie 'ap'ron and 'thro'ugh the front-rolls; i eripheral speed for the-front rolls Was-"approximately 480%? of e speed-of themiddle rolls" and the:composite yarn waswcolleeted on a single spindle after being tWistedapproximately 3 turns per inch.-

The yarn thus produced showed remarkable elasticity, low twist and normal textileprocessingproperties. A yarn of 4.87 number.(cotton system) (Was obtained which showed a..tensile strength of 1422 grams-and an.elo ngation ot' 65.% at break. The ammus. producedwas woven into construction typified ilbygsoftl filledsheetings of a count 42 W x 40 This soft. filled sheetingjwas napped completely in only two passes throughalnapper whereas-several more passes would'normally beexpe'cted to be required to produce a nap offequalquality and produced a soft'open textured 'fiannelIwith. surface fibersalmost whollycomposed of nylon. When placedinboili'ng water, this fabric shrank almost instantaneously to provide to produce a-fabricof'62- W'X-42-F COl1nt.

Example 5 A 20 filament tow of non-elongated polyethylene having a denier of 700 was supplied to a conventional cotton spinning frame co-inciden'tally with a five hank roving of 1%" staple cotton and the two were carried together to the middle roll of the frame, over the apron and through the front roll. The peripheral speed of the front rolls was approximately 480% of the speed of the middle rolls and the composite yarn was collected on a single spindle after being twisted apprximately 3 turns per inch. 7

Yarns thus produced showed remarkable elasticity, low twist and normal textile processing properties. Yarns of 5.7 number (cotton system) were obtained which showed uniformly a tensile strength of 850 grams and an elongation of 22.2% at break. The dyeing properties were distinctly those of cotton.

Example 6 A filament tow of non-elongated polyethylene having a total denier of 365 was supplied to a conventional cotton spinning frame co-incidentally with a seven hank roving of 1%, staple cotton and the two were carried together to the middle roll of the frame, over the apron and through the front roll. The peripheral speed of the front rolls was approximately five times the speed of the middle roll and the composite yarn was collected on a single spindle after being given a twist multiplier of 4.00 to produce a yarn of 24s single (calculated). The yarn thus produced had considerable elasticity, low twist and normal textile processing properties. However, due to some residual contraction in the polyethylene the yarn number was actually 21 singles. The singles yarn was plied to produce a 3-ply yarn.

Example 7 A 20 filament tow of non-elongated polyethylene having a denier of 700 was supplied to 'a'conventional cotton spinning frame co-incidentally with a Vinyon-N roving of 3 denier, 1.5" staple and thetwo were carried together to the middle roll of the frame, over the apron and through the front roll. The peripheral speed of the front rolls was approximately 480% of the speed of the middle rolls and the composite yarn was collected on a single spindle after being twisted approximately 3% turns per inch.

The composite yarn thus prepaired possessed, in addition to the desirable properties of high strength, good hand, appearance and the like, the property of being non-inflammable.

The composite yarn thus produced was woven into a fabric, napped and then shrunken in boiling water. The

highly 'nappe'd' fabric: thus produced:'would rnot: burn 2 and did not sufferfromi flash" fire hazards;

It" isto: be: understood; the:- foregoing: examples are merely illustrative and that many variations and :changes will occur-rtoathose skilled" initherart upon" reading this descriptiom' All:..such. changes: and variations are in;v tended ito comeiwithin :the scope of the :inventionafasrde-r fined .in itheappended claims.

Iclaim:

l. A method.offlproducingua:compositenyarn having the appearance of a staple yarn, which: comprises don-z bling and codrafting a tow of incompletely oriented,".continuous and highly .extensible filaments with: an assemblage of potential yarn; components, I said drafting operation being sufficient uto elongate permanently by'ab least about 100% and'highly'orient but not breakthefilaments in the previously "incompletely 1 oriented filamentsg; and twistingthe yarn thus-produced.

2. A method of producing a composite. yarnzhaving the appearance of a staple yarn, which. comprisesdoubling a first tow of. incompletely. oriented, continuous: and highly 'extensible filaments with a second-tow OfCOIl'e' tinuous filaments of substantially lower extensibility, drafting the doubled tows to elongate permanently by at least about 100% and highly orient but not break the filaments in the first tow and to break the filaments in the second tow, and twisting the yarn so produced.

3. A method of producing a composite yarn having the appearance of a staple yarn, which comprises doubling a first tow of incompletely oriented, continuous and highly extensible filaments with a second tow of continuous filaments having an extensibility substantially no greater than about half the extensibility of the highly extensible filaments, drafting the doubled tows to elongate permanently by at least about 100% and highly orient but not break the filaments in the first tow and to break the filaments in the second tow, and twisting the yarn so produced.

4. A method of producing a composite yarn having the appearance of a staple yarn, which comprises predrawing a tow of highly extensible, unoriented filaments an amount insufficient to orient them completely, doubling said predrawn tow with a tow of continuous filaments having an extensibility substantially less than the extensibility of the incompletely oriented filaments, drafting the doubled tows to elongate permanently by at least about and highly orient but not break the filaments in the first tow and to break the filaments in the second tow, and twisting the yarn so produced. A

5. A method of producing a composite yarn having the appearance of a staple yarn, which comprises doubling a first tow of incompletely oriented, continuous and highly extensible filaments having a given breaking point after elongation by a given amount with a second tow of continuous filaments of substantially lower'extensibility having a breaking point substantially equal to said given breaking point after staplization and elongation by said given amount, drafting the doubled tows to elongate them said given amount to highly orient but not break the filaments in the first tow and to break the filaments in the second tow, and twisting the yarn so produced.

6. A method of producing a composite yarn having the appearance of a staple yarn, which comprises doubling a first tow of incompletely oriented, continuous and highly extensible filaments with a second tow of continuous filaments of substantially lower extensibility, drafting the doubled tows an amount suflicient to elongate permanently by at least about 100% and orient and impart maximum tensile strength to the filaments in the first tow without breaking them and to break the filaments in the second tow, and twisting the yarn so produced.

7. A method of producing a composite yarn having the appearance of a staple yarn, which comprises doubling a tow of incompletely oriented, continuous and highly extensible filaments with a roving of staple fibers, drafting the doubled tow and roving to highly orient but not break the filaments in the tow, and twisting the yarn so produced.

8. A method of producing a composite yarn having the appearance of a staple yarn, which comprises predrawing a tow of highly extensible, unoriented filaments an amount insuflicient to orient them completely, doubling said predrawn tow with a roving of staple fibers, drafting the doubled tow and roving to highly orient but not break the filaments in the tow, and twisting the yarn so produced.

9. A method of producing a composite yarn having the appearance of a staple yarn, which comprises doubling a tow of incompletely oriented, continuous and highly extensible filaments with a roving of staple fibers, drafting the doubled tow and roving an amount sufiicient to orient and impart maximum tensile strength to the continuous filaments Without breaking them, and twisting the yarn so produced.

10. A low twist, composite yarn combining the high strength characteristics of oriented continuous filament yarns with the hand, appearance, dyeing characteristics and weaving properties of staple yarns, said composite yarn comprising a number ofhighly oriented, continuous filaments and a plurality of staple fibers firmly anchored thereto and resistant to peeling, the continuous filaments and staple fibers having substantially a single break, upon tensioning to the breaking point.

References Cited in the file of this patent UNITED STATES PATENTS 1,976,201 Taylor Oct. 9, 2,044,130 Sowter June 16, 1936 2,130,948 Carothersv Sept. 20, 1938 2,132,524 Booth Oct. 11, 1938 2,313,058 Francis nu. Mar. 9, 1943 2,433,722 Weiss Dec. 30, 1947 2,477,652 Robbins Aug. 2, 1949 2,517,946 Von Kohorn Aug. 8, 1950 2,526,523 Weiss Oct. 17, 1950 FOREIGN PATENTS 415,054 Great Britain Aug. 15, 1934 

6. A METHOD OF PRODUCING A COMPOSITE YARN HAVING THE APPEARANCE OF A STAPLE YARN, WHICH COMPRISES DOUBLING A FIRST TOW OF INCOMPLETELY ORIENTED, CONTINUOUS AND HIGHLY EXTENSIBLE FILAMENTS WITH A SECOND TOW OF CONTINUOUS FILAMENTS OF SUBSTANTIALLY LOWER EXTENSIBILITY, DRAFTING THE DOUBLED TOWS AN AMOUNT SUFFICIENT TO ELONGATE PERMANENTLY BY AT LEAST ABOUT 100% AND ORIENT AND IMPART MAXIMUM TENSILE STRENGTH TO THE FILAMENTS IN THE FIRST TOW WITHOUT BREAKING THEM AND TO BREAK THE FILAMENTS IN THE SECOND TOW, AND TWISTING THE YARN SO PRODUCED. 